1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Scratch Build - In Progress ⭐ carbon fiber , aluminum and purple

Discussion in 'Project Logs' started by usagi, 19 Jun 2016.

  1. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello everybody
    My name's Jean from France.


    i want to share my projet :
    carbon fiber , aluminum and purple .



    a carbon fiber pc case , with some parts in aluminum and some painting parts ....

    no screw outside

    [​IMG]



    in fact , this projet has been start and stop few years ago ( march 2011) with a mac pro apple , named " furyo " based on " jojo bizarre adventure " .....

    i was really difficult to find time for the mod .

    this time everything is ok !

    and again , For the design, I will use my inspiration of "JoJo's Bizarre Adventure" by Hirohiko Araki , my favourite japanese manga Illustrator...


    it will be my personnal pc ,not just a "mod " , and i absolutely need a new atx pc case .

    sorry in advance for my poor English.

    I do not have the skills for illustrations 3d pictures....sorry



    i started today by make a Pattern by Hand.


    - this a block of Polyurethane block .
    [​IMG]



    - block of Polyurethane with Aerocool DS Cube

    [​IMG]



    - it needs to be cut in three parts with my japanese saw .....

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]




    - some cleaning

    [​IMG]



    - now , need to be glued in one block ....
    i didn't make phtographies because , i had few seconds to glue parts ....

    [​IMG]



    - done ....glued ....in one block , the first form . I equalized forms

    [​IMG]

    [​IMG]



    - sanded with sanding block and Abrasive Paper

    [​IMG]



    - sanded ....
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]






    - and after some hours of sanding , i have my first form .

    i was tired and i prefered to stop now before make an error .....

    [​IMG]


    it complicated to give forms by hand and it takes time , and it's the most important step : the design of my pc pcase ....

    See you later
    jean
     
    Last edited: 9 Mar 2017
  2. Dot_Kappa

    Dot_Kappa 100% Puppet

    Joined:
    23 Mar 2006
    Posts:
    238
    Likes Received:
    18
    Carbon fiber and aluminium...interesting!

    Subbed
     
  3. gnidnu

    gnidnu Beware of the Tofu!

    Joined:
    9 May 2006
    Posts:
    51
    Likes Received:
    0
    Instasubb. Very curious how it will turn out.
    Is the foam going to be the actual core itself or the primary mould for it?
     
  4. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello everybody


    thank you Dot_Kappa and gnidnu :eek:




    gnidnu
    " Is the foam going to be the actual core itself or the primary mould for it? "

    it will be the primary mould to apply carbon fiber after .


    I started to cut pieces of aluminum today , i will post an update with some beautiful photographies tomorrow ( I don't like to use my camera when i work .... aluminum dust .)



    See you later
    jean
     
  5. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello everybody

    a little update

    after several hours of work, here are the results.... but not finished .

    it's a 3 mm aluminium thickness
    [​IMG]



    I work with a jewellery saw...

    [​IMG]


    [​IMG]


    [​IMG]


    the test , maybe a bit big :eek:

    [​IMG]

    [​IMG]

    [​IMG]


    See you later
    jean
     
  6. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello
    some updates today .
    I finally decided to keep this design....


    [​IMG]

    [​IMG]

    [​IMG]


    I applied a hard bodyfiller today, to give a first hard layer.
    [​IMG]

    [​IMG]



    rear
    [​IMG]
    [​IMG]



    front


    [​IMG]
    [​IMG]


    it will be sanded and after , i will apply again 2-3 finishing body filler .

    bye
    jean
     
    Last edited: 30 Jun 2016
  7. Vetalar

    Vetalar *learning english*

    Joined:
    21 Jun 2011
    Posts:
    577
    Likes Received:
    9
    subbed
     
  8. storm-83

    storm-83 Member

    Joined:
    7 Nov 2014
    Posts:
    451
    Likes Received:
    14
    Home build speakers in the back?
    Looks like a fun project, will be keeping an eye on it!
     
  9. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    Hello
    After several months of absence.






    I changed the design of my project, based on micro -atx , I prefer to stay on the "compact atx" ,
    with a new design


    [​IMG]


    Temperatures are better now in France , for working composite materials.

    after a first layer of "black" Coat Primer , sanding , I close the imperfections with "white" body filler


    front
    [​IMG]


    rear
    [​IMG]


    again sanding
    [​IMG]

    front
    [​IMG]

    A glossy finish to seal the porosity of the putty ..
    [​IMG]


    Sanding the imperfections...
    [​IMG]


    I stop there for the finish of the prototype . it's enough, and it costs a lot in product...:eek:


    a final layer of PVA for easy demolding.....
    [​IMG]
    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    and my mold is finish , and ready for carbon layer , after few months ! :blush:



    [​IMG]











    storm-83 :D

    yes , it's an old tannoy Berkeley 385 ....i made my self the cabinet , like " vox ac30 handwired head " :blush:



    ps: sorry for my poor English :blush:
     
  10. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello
    a little update
    and the most difficult part : cut the carbon fiber .


    I have to fix the lines of cut with tape.
    To prevent the screen from moving ...

    i don't like this part
    [​IMG]

    Cut wide, without losing too much material...
    I spent 1 hour and a half to finish

    i use 2 types

    1 Carbon Fibre Twill , the most known....
    [​IMG]

    I appreciate carbon for its qualities , but i don't like "design racing "...


    that is why i will use this other carbon , to "cover" the project ..
    [​IMG]

    [​IMG]


    now , i need to glue all these sheets all around the "mold "....
    [​IMG]

    bye
     
  11. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello

    sorry for my poor english , complicate to explain this kind of work
    Stratification and realization of the case....

    in first time , i need to fix the "Peel Ply " all around the surface of the prototype , it will give me a "raw surface " inside the case ....

    [​IMG]
    [​IMG]


    each side of the case , i fix "Vacuum Bagging Gum Sealant Tape" ......
    [​IMG]


    now i can start to lay the differents carbon layers....

    in first , a "raw carbon " for inside of the case .
    [​IMG]
    [​IMG]


    the "rear of the case ...
    [​IMG]

    the most important " Carbon Fibre Twill " x 5 layers ....
    [​IMG]
    [​IMG]
    to fix the " carbon layers , i use glue in "spray can" ...

    the "rear of the case ...
    [​IMG]

    Pretty curve
    [​IMG]


    The thickness increases, it is more difficult, to fix ...

    and the final touch , a "raw carbon" ......

    [​IMG]
    [​IMG]

    not really perfect ...
    [​IMG]
    [​IMG]



    a final "Peel Ply "
    [​IMG]
    [​IMG]

    and finsih !!!
    [​IMG]


    I let " breathe" one day, and I attack the " vacuuming "

    bye
     
  12. Cheapskate

    Cheapskate Insane? or just stupid?

    Joined:
    13 May 2007
    Posts:
    10,626
    Likes Received:
    760
    :thumb:
    Watching and learning.
     
  13. Cleveland216

    Cleveland216 Carbon Fiber King

    Joined:
    30 Dec 2007
    Posts:
    529
    Likes Received:
    19
    You can use Spray Adhesive between layers to hold them down. Take your time installing the bag and really look at your flow line lay out. No Flow, No Complete Part. If you have any questions, I'm always around.
     
  14. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello


    thank you

    Cheapskate :thumb:


    Cleveland216 for your help :dremel:

    things are moving ....


    a few days ago ..

    "prototype" under vacuum

    And inclusion resin , and fews days to wait .....

    [​IMG]



    The pictures arrive...

    :clap:

    ps: i'm sorry for my poor English
     
  15. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello




    a big update , 50 % of my scratch is done !


    shadow


    [​IMG]



    after removing Vacuum Bagging Film , the carbon and resin are "hard"

    [​IMG]



    [​IMG]


    now , I need to cut and remove the excess carbon on each side.... for a 20.5 cm large .


    [​IMG]



    Prepare to cut ...

    [​IMG]





    tadaaaaaaa !!! after few hours of cutting and sanding...


    [​IMG]




    The parts removed

    [​IMG]




    final form
    The case looks too much small with 21 cm large compare to the prototype with 35cm large ....but it's a normal size .


    [​IMG]




    for the moment , I don't remove the "core " , I need to sand "surface" before ...


    [​IMG]




    the next stage : make a beautiful finish and protect carbon..


    bye :clap:
     
  16. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    salut

    little update :blush:


    I never talk about my new design , this is what I want to do for my "personal" pc

    no screw outside

    [​IMG]


    bye
     
  17. Cheapskate

    Cheapskate Insane? or just stupid?

    Joined:
    13 May 2007
    Posts:
    10,626
    Likes Received:
    760
    Congratulations on a successful molding. :D
    Sketch: You should move the back "feet" forward of the PSU notch.
     
  18. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    salut / hello everybody



    thank you Cheapskate


    I hesitate for rear "design " I'm not satisfy...
    i want to keep the "visual" and not hide this special design...





    the "prototype" is destroyed and removed ....


    [​IMG]





    for this final result


    [​IMG]



    [​IMG]



    [​IMG]




    with psu ...


    [​IMG]



    it's really just ....:blush:


    [​IMG]



    with mb....... this is not a "real" atx form , it's only 22cm large ...


    [​IMG]



    I had a problem with finish surface after sanding ...
    some "lines" inside the "raw carbon" appear and destroy visual ...
    I will remove this "final layer " or try with covering ...



    really disappointed :(

    [​IMG]



    this is I want to my scratch build

    [​IMG]


    no water-cooling , a big dual tower rad ...
    full atx
    a slot -in cd
    2 hdd max
    4 ssd
    enough place for a 20 cm tall psu



    I'm not a gamer , 25 cm for a graphic card is enough for me

    [​IMG]


    to compare
    [​IMG]


    now I need to remove this bad "finish "....:grr:



    forgive me for my bad English :blush:


    bye
     
  19. Dot_Kappa

    Dot_Kappa 100% Puppet

    Joined:
    23 Mar 2006
    Posts:
    238
    Likes Received:
    18
    Did you use some core material or just layer and layer of pure carbon fiber ?

    It seems very thick, at least 4mm or I am wrong
     
  20. usagi

    usagi New Member

    Joined:
    3 Mar 2011
    Posts:
    25
    Likes Received:
    0
    hello :blush:
    a little update after few days

    I prefer to wait the "good weather" and this is not always the case in France .... and I prefer to work on "little pieces " .


    I started working on dvd support...


    I directly moulded on the case, to have an "identical" shape
    the case is "protected" to not bond with dvd support ...

    [​IMG]



    [​IMG]



    [​IMG]



    a little 2 ssd support


    [​IMG]





    and a heavy back plate I/O support


    [​IMG]



    under vacuum and resin


    [​IMG]





    after few days and demold ....



    [​IMG]



    it's a 35 cm x 15 cm x 13 mm for 1028 gr !



    [​IMG]



    It will not be glued , it costs me a lot of money ! , It will be a removable part, which I will be able to recover for a "possible future mod" or V2 :idea: ....


    I still have to do

    2 doors

    1 cover for a atx psu

    1 little cover for a sfx psu

    a wood cover for the dvd support

    7 pci plate covers "alu"

    a final " layer " for my case with my new beautiful carbon" !


    hello Dot_Kappa

    it's just layer and layer of pure carbon fibre , because if I add a
    "core material " , it will be see ,and not beautiful ...


    thickness is only 2.7 mm , I think is really "just" and I will add a final "layer" ,with a final "cover" layer with a "beautiful carbon I received these days , I will add some pictures later ...


    forgive me for my bad English

    bye
     

Share This Page